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Abstract:

The present invention relates to a lens for use with a lamp having at
least one LED light source. The lens preferably includes a plurality of
projections each having a substantially flat top surface and a plurality
of sloping side surfaces, preferably suitable for dispersing the emitted
light. Such a variance in light emission may enhance the light being
viewed from different angles and positions therefrom.

Claims:

1. A transparent lens mountable to a light source having one or more
light emitting diodes (LEDs), the lens comprising a base and one or more
projections, wherein each projection is aligned with an LED and includes
one or more sloping side surfaces forming an obtuse angle with the base
for dispersing the emitted light in different directions, and a top
surface across the projection for directing light in at least a direction
substantially perpendicular to the base.

2. The lens of claim 1, wherein the top surface magnifies the light
transmitted therethrough.

3. The lens of claim 1, wherein each projection has four adjacent side
surfaces, each directing light in a direction distinct from every other
adjacent side surface.

4. The lens of claim 1, wherein the side surfaces are smooth.

5. The lens of claim 1, wherein the side surfaces have a plurality of
striations.

6. The lens of claim 1, wherein the side surfaces slope in toward the
direction of the emitted light.

7. The lens of claim 1, wherein the side surfaces are curved.

8. The lens of claim 1, wherein the side surfaces are planar.

9. The lens of claim 1, wherein the base comprises a plurality of rings
bordering each projection.

10. The lens of claim 1, wherein the base comprises a plurality of
grates.

11. The lens of claim 1, wherein the projections have one or more steps.

12. The lens of claim 1, wherein the steps are rotated relative to one
another.

13. The lens of claim 1, wherein the lens is constructed and arranged to
enclose a single LED.

14. The lens of claim 1, wherein the lens is constructed to be mountable
on a stop/tail/turn lamp of a vehicle.

15. A lamp assembly comprising: one or more LEDs; a housing wherein the
one or more LEDs is located; and a lens according to claim 1 mounted on
the housing.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. application Ser. No.
11/450,798, filed on Jun. 8, 2006, entitled "LENS FOR LED LAMPS," which
claims the benefit of U.S. Provisional Application No. 60/760,821, filed
on Jan. 20, 2006, entitled "LENS FOR LAMPS FOR A VEHICLE," which are both
hereby incorporated in their entirety by this reference.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to a lens for use with light-emitting
diode (LED) light sources, for example, light fixtures and lamps such as
free standing lamps, stop/tail/turn lamps for vehicles, etc. More
particularly, the present invention relates to a lens having a structure
suitable for maintaining or magnifying the intensity of light emitted
from the LED as well as to facilitate dispersing the emitted light.

[0003] One of the problems associated with using a light-emitting diode
(LED) light source, for example, in a lamp for a vehicle, is the
difficulty in spreading the illumination in a longitudinal direction,
i.e., an arc-like pattern. While LEDs are often preferred because they
can have an operating life of up to 100,000 hours before degradation
commences, the light emitted from LEDs is in a narrow cone-shaped
pattern. More specifically, an LED is a directional light source in which
light is emitted in a direction generally perpendicular from the light
source. The amount of longitudinal dispersion is minor compared to an
incandescent bulb. A typical radiation pattern for an LED is within
approximately 20° of the direction generally perpendicular from
the light source. Therefore, LED lamps or light fixtures may be
insufficient for adequately illuminating an area, such as a room, a
hallway, an outdoor area, etc.

[0004] Vehicles, such as an automobile or truck/trailer combination
typically have stop/tail/turn lamps on the front and/or the rear of the
vehicle, to indicate that the vehicle is stopping, turning, changing
lanes, etc. The stop/tail/turn lamps typically include a housing, which
includes the light source, and a lens, which protects the light source
from the natural elements. Typically, the light source is either a
standard high-intensity incandescent bulb, which has a relatively short
life span and is susceptible to damage, or an LED, which has a greater
operating life. However, the narrowness of the emitted light can render
LEDs less than completely satisfactory for use in stop/tail/turn lamps.

[0005] Thus, there exists a need to provide a lens suitable for use with
an LED light source, such as a lamp, a light fixture, stop/tail/turn
lamp, etc. which is relatively inexpensive and easy to manufacture and
which in combination with the LED can provide sufficient illumination,
for example for use on a vehicle.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a lens for use with LED light
sources, for example, light fixtures and lamps such as freestanding
lamps, stop/tail/turn lamps for vehicles, etc. In one embodiment of the
invention, the lens of the present invention includes a plurality of
projections each having a substantially flat top surface, preferably
suitable for magnifying the emitted light, and a plurality of sloping
side surfaces, preferably suitable for dispersing the emitted light. In a
preferred embodiment of the invention, each projection has multiple
sloping side surfaces, which preferably vary the direction of light
emission, for example, by refracting the light being transmitted through
the sloping side surfaces of the lens. Therefore, the light being emitted
by the LED can be transmitted in various directions, thus increasing the
area that is illuminated by the LED in comparison to an LED without such
a lens. In accordance with one embodiment of the invention, each
projection is substantially aligned with an LED. Such a variance in light
emission may enhance the light being viewed from different angles and
positions from the light source. Namely, by transmitting the light at a
variety of angles from the LED, the light can be seen at various angles
from the light source, rather than being limited to positions
substantially perpendicular to the light source.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The particular features and advantages of the invention as well as
other objects will become apparent from the following description taken
in connection with the accompanying drawings, in which:

[0008] FIG. 1A is a top plan view of a lamp assembly in accordance with
one embodiment of the present invention;

[0009] FIG. 1B is a cross-sectional view of the lamp assembly of FIG. 1A
taken along section line A-A of FIG. 1A;

[0010] FIG. 2 is a magnified view of a selected portion of the lamp
assembly of FIG. 1B;

[0011] FIG. 3 is a front perspective view of a lens in accordance with one
embodiment of the present invention;

[0012] FIG. 4 is a front perspective view of a projection in accordance
with one embodiment of the present invention;

[0013] FIG. 5 is a top plan view of a lens in accordance with one
embodiment of the present invention.

[0014] FIG. 6 is a side elevational view of a lens in accordance with one
embodiment of the present invention;

[0015] FIG. 7 is a top plan view of a lens in accordance with one
embodiment of the present invention;

[0016] FIG. 8 is a top plan view of a projection in accordance with one
embodiment of the invention;

[0017] FIG. 9 is a side elevational view of a lens in accordance with one
embodiment of the present invention; and

[0018] FIG. 10 is a side elevational view of a lens in accordance with one
embodiment of the present invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0019] Certain exemplary embodiments of the present invention will now be
described with reference to the drawings. In general, such embodiments
relate to a lens containing one or more projections for outwardly
directing light emitted from an LED light source.

[0020] Referring to FIGS. 1A-7, in accordance with certain embodiments of
the invention, a lens 10, which includes a base 12 and a plurality of
projections 100, is particularly suited for use with an LED light source.
Whereas base 12 can be substantially flat and round, as depicted in FIGS.
1A, 3, 5 and 7, it is to be understood that base 12 can comprise a
variety of shapes, smoothness, flatness, include bumps, etc., without
deviating from the scope of the invention, as a matter of application
specific to design choice. For example, for use with a stop/tail/turn
lamp of a vehicle, it is preferable for base 12 to take on the shape of
the stop/tail/turn lamp, which is typically round or oval, having a
diameter of between about 2-6 inches, preferably about 4 inches. In
contrast, a lens for use with a light fixture can be any shape or size.

[0021] Referring to FIGS. 1-8, projections 100 preferably comprise a
translucent material that can transmit, more preferably disperse, light
emitting from an LED light source, such as but not limited to
polycarbonate, acrylic, etc. Accordingly, it is preferred to position at
least one LED light source substantially aligned with a projection 100.
As shown in FIGS. 1A-10, an embodiment of projection 100 has a
substantially flat top surface 110 substantially parallel to the base.
Accordingly, light emitted from the LED can be transmitted in a direction
substantially perpendicular to the base through top surface 110. More
preferably, top surface 110 can magnify the intensity of the light
emitted from the LED.

[0022] A preferred embodiment of projections 100 also includes a plurality
of side surfaces 120 which can direct light in a direction different from
light being transmitted through flat top surface 110. The direction of
light preferably depends on the angle at which side surface 120 meets
base 12. As shown in FIG. 8, side surfaces 120 can have a plurality of
striations 121 to facilitate dispersing the light. In accordance with a
preferred embodiment of projections 100 as illustrated, each projection
100 includes at least 3, preferably 4 side surfaces 120. Preferably, side
surfaces 120 are arranged at an acute angle to the area under the
projection coplanar with base 12, more preferably at an angle of less
than about 45 degrees. Whereas side surfaces 120 of projections 100 are
illustrated as having substantially equal angles with base 12, it is to
be understood that various side surfaces 120, for example, side surfaces
120 of different projections 100, can form different angles with base 12
without deviating from the scope of the invention as a matter specific to
design choice.

[0023] In accordance with a preferred embodiment of the invention,
projections 100 are arranged so that side surfaces 120 of different
projections 100 direct light in different directions. Preferably, no two
side surfaces 120 are parallel, thereby increasing the number of
directions in which the light is directed by lens 10. For example, as
shown in FIG. 7, an embodiment of lens 10 has nine projections 100 having
four side surfaces 120 each. In this embodiment, no two side surfaces 120
are parallel, thus providing thirty six different directions at which
light is transmitted through the collective side surfaces 120.

[0024] As illustrated in FIGS. 5 and 6, an embodiment of lens 10 comprises
a base diameter D1 greater than both projection diameter D2 and
projection height H. In accordance with a preferred embodiment of the
invention for use with a stop/tail/turn lamp, base diameter D1 is between
about 2 to 6 inches, more preferably about 4 inches. Whereas the
embodiments of lens 10 shown in FIGS. 1A, 5 and 7, which are examples of
lens 10 for use with stop/tail/turn lamps, include 3, 6 and 9 projections
100, respectively, it is to be understood that the number of projections
100 is not limited and can be as many or few as desired.

[0025] In accordance with an embodiment of the invention, for example, as
illustrated in FIGS. 1A-2, lens 10 can be positioned such that base 12 is
substantially perpendicular to the LED light source. Therefore, the
direction of the light path of the emitted light remains substantially
the same at top surface 110. Preferably, the light intensity is magnified
through top surface 110. Additionally, the light paths are preferably
redirected through side surfaces 120 according to the angle of side
surfaces 120 of projections 100. Therefore, the light emitted from the
LED(s) can be dispersed to provide a broader area of emitted light, and
the light can furthermore be seen from various angles from the LED(s) and
lens 10. More preferably, the light passing through side surfaces 120 is
further dispersed by striations 121 included in side surfaces 120,
thereby further dispersing the emitted light. Therefore, a potential
benefit of a lens in accordance with embodiments of the invention shown
in FIGS. 1-8 includes, but is not limited to, the production of at least
one magnified beam of light perpendicular to the light source as well as
dispersed light at various angles from the light source, thus increasing
the number of positions with respect to the light source from which the
light is visible.

[0026] As shown in FIG. 7, base 10 can comprise a plurality of grates 17,
preferably arranged as concentric rings. Base 10 can also include a
plurality of rings 15 bordering projections 100, preferably a set of
rings 15 bordering each projection 100. Grates 17 and rings 15 preferably
also disperse the light emitted from the LED's and help produce a glowing
effect on the lens. It is to be understood that, however, grates 17 can
be arranged in a variety of arrangements, such as parallel lines, curved
lines, etc., and similarly, rings 15 can comprise different shapes and
arrangements, without deviating from the scope of the invention as a
matter of application specific to design choice.

[0027] In accordance with a preferred embodiment of the invention as shown
in FIG. 7, projections 100, preferably every projection 100 on lens 10,
are surrounded by concentric rings 15 suitable for dispersing light.
Rings 15 can be formed of grooves, grates, steps, ripples, etc. suitable
for enhancing the dispersion of light and creating a glowing effect
around projection 100.

[0028] Whereas projections 100 are depicted as having a circular base
wherein the base diameter is greater than the height of the projections,
the dimensions and shape of projections 100 and its base can be varied
without deviating from the scope of the invention as matter of
application specific to design choice. For example, projections 100 can
have a generally pyramidal shape without deviating from the scope of the
invention.

[0029] Referring to FIG. 9, an embodiment of a lens 20 having a lens base
212 and a projection 200 is shown. In accordance with the embodiment
shown, the projection 200 includes an upper portion 201 and a lower
portion 202. Upper portion 201 comprises a top flat surface 210 and top
side surfaces 220, and lower portion 202 comprises lower side surfaces
221. A substantially flat step 211 is preferably located between top side
surface 220 and lower side surface 221.

[0030] Top surface 210 of the lens of FIG. 9 is preferably substantially
flat, as illustrated, and more preferably is constructed to magnify the
light being emitted therethrough. It is also preferable for step 211 to
also be constructed to magnify the light being emitted therethrough. In
accordance with a preferred embodiment of the invention, both top surface
210 and step 211 do not change the direction of the light, thus providing
a plurality of beams of light perpendicular to the light source for each
projection 200.

[0031] Potential benefits of a stepped projection 200 as illustrated in
FIG. 9 include but are not limited to the production of more than one
magnified, concentrated, direct beam of light perpendicular to the light
source, as well as providing greater dispersion of light. In accordance
with one embodiment of the invention, upper side surface 220 and bottom
side surface 221 form different angles with base 212, thereby further
enhancing the dispersion of light being emitted through lens 20 by
providing an additional angle at which the emitted light is dispersed.
Furthermore, upper portion 201 can be in a rotated relationship with
lower portion 202, thus varying the directions at which light is
dispersed.

[0032] In accordance with an embodiment of the invention shown in FIG. 10,
lens 30 does not need to be constructed to be placed above a housing
containing LEDs. Whereas these constructions are within the scope of the
invention, for example, as illustrated in FIGS. 1A-2, it is to be
understood that other constructions are also encompassed by the
invention, such as lens 30 constructed to be positioned proximate the
LEDs, for example, to enclose a single LED 31 as shown in FIG. 10.

[0033] Referring to FIG. 10, lens 30 can comprise a base 330 having a
generally cylindrical shape suitable for maintaining a projection 300
above LED 31. It is to be understood that base 330 need not be
cylindrical, but can take on various shapes and sizes, such as a
rectangular shape, and furthermore need not enclose LED 31 and can
comprise rods, apertures, etc., without deviating from the scope of the
invention. Lens 30 can be used either alone or in combination with a
protective member.

[0034] Lens 30 can also include projection 300 having a plurality of side
surfaces 320 suitable for dispersing light. Projection 300 preferably
also includes a substantially flat, top surface 310, which more
preferably magnifies the emitted light. It is to be understood that
projection 300 is not limited to the embodiment illustrated in FIG. 10
and can comprise different shapes, one or more steps, striations, etc.
without deviating from the scope of the invention.

[0035] Lens 10, 20, 30 and any components thereof can be made from any
material that allows light to pass through it, such as, for example, any
translucent or transparent material, including but not limited to glass,
acrylic or plastics. In one embodiment of the present invention, lens 10
is produced using a polycarbonate. In another embodiment of the
invention, lens 10 can be produced using acrylic.

[0036] FIGS. 1A-2 show a lamp assembly in accordance with an embodiment of
the invention. More specifically, lamp assembly 11 comprises a housing 2
which can surround one or more LEDs 1, and a lens 10 having base 12 and
projections 100. It is preferable for each projection 100 to be at least
substantially aligned to one LED 1, as depicted in FIG. 2, which shows a
magnified view of area B of FIG. 1B. Such an alignment can be preferred
because the light emitted from LED 1 can travel in direction C, at which
the emitted light is its strongest, through projection 100, after which
the direction remains constant, thus maintaining the maximum intensity of
the emitted light.

[0037] Thus, while there have been shown and described and pointed out
novel features of the present invention as applied to preferred
embodiments thereof, it will be understood that various omissions and
substitutions and changes in the form and details of the disclosed
invention may be made by those skilled in the art without departing from
the spirit of the invention. For example, projections 100 can comprise a
different shape, for example, it can comprise a triangular or rectangular
base shape, etc., without deviating from the scope of the invention as a
matter of application specific to design choice. Additionally, other
alterations can be made, as a way of non-limiting example, varying the
number of LEDs, altering the transparency of lens 10 or projections 100,
depending on the desired illumination, as a matter of application
specific to design choice, without deviating from the scope of the
invention. It is the intention, therefore, to be limited only as
indicated by the scope of the claims appended hereto.

[0038] It is also to be understood that the following claims are intended
to cover all of the generic and specific features of the invention herein
described and all statements of the scope of the invention which, as a
matter of language, might be said to fall therebetween.